Contribution to the Full 3D Finite Element Modelling of a Hybrid Stepping Motor with and without Current in the Coils

The paper presents our contribution to the full 3D finite element modelling of a hybrid stepping motor using COMSOL Multiphysics software. This type of four-phase motor has a permanent magnet interposed between the two identical and coaxial half stators. The calculation of the field with or without current in the windings (respectively with or without permanent magnet) is done using a mixed formulation with strong coupling. In addition, the local high saturation of the ferromagnetic material and the radial and axial components of the magnetic flux are taken into account. The results obtained make it possible to clearly observe, as a function of the intensity of the bus current or the remanent induction, the saturation zones, the lines, the orientations and the magnetic flux densities. 3D finite element modelling provide more accurate numerical data on the magnetic field through multiphysics analysis. This analysis considers the actual operating conditions and leads to the design of an optimized machine structure, with or without current in the windings and/or permanent magnet.

3D Finite Elements Technique for Collapse Causes of the Pylons in Egyptian Temples: A Study of the Great Pylon of Ramesseum Temple, Luxor, Egypt

This research presents damage causes of the pylons in the ancient Egyptian temples based on 3D finite elements analysis. The main purpose of the research determines the failure causes of the first pylon of the Ramessium temple, which is situated in Upper Egypt, at Luxor “Thebes” on the west bank of the Nile River. The first pylon of Ramessium temple subjected to seismic activity effects on long term, combined with several structural damage factors such as the defects resulting from the construction technique, where the builder used the poor quality of stones in foundations of the pylon, the building materials residue was used as filler for the core of the pylon walls, and it lacked vertical joints between the courses. In addition to it founded on alluvial soil that is vulnerable to contaminated water, it is still suffering damage factors and urban trespasses at the moment. All of the former factors helped the pylon to be affected by the earthquakes loads that occurred on it. The structural behavior of the pylon under self-weight and earthquakes loads were carried out by Numerical analysis to find out the loads and stresses which caused collapsing of the pylon. Results of the study indicated that the pylon subjected to a horizontal displacement due to old earthquakes force, led to collapse of the pylon. Finally, the study represents use of modern technique to study the structural behavior of the most important architectural units in ancient Egyptian temples to identify the causes of its collapse.

Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

Prediction of Weld Joint Shape and Dimensions in Laser Welding Using a 3D Modeling and Experimental Validation

This paper presents an experimentally validated weld joint shape and dimensions predictive 3D modeling for low carbon galvanized steel in butt-joint configurations. The proposed modelling approach is based on metallurgical transformations using temperature dependent material properties and the enthalpy method. Conduction and keyhole modes welding are investigated using surface and volumetric heat sources, respectively. Transition between the heat sources is carried out according to the power density and interaction time. Simulations are carried out using 3D finite element model on commercial software. The simulation results of the weld shape and dimensions are validated using a structured experimental investigation based on Taguchi method. Experimental validation conducted on a 3 kW Nd: YAG laser source reveals that the modelling approach can provide not only a consistent and accurate prediction of the weld characteristics under variable welding parameters and conditions but also a comprehensive and quantitative analysis of process parameters effects. The results show great concordance between predicted and measured values for the weld joint shape and dimensions.

Mechanical Validation of Perfect Tibia 3D Model Using Computed Tomography Scan

In this paper, the Von Mises stresses and stiffnesses measured by experiments on a human cadaveric tibia and composite ones compared to those predicted by a FE model based on the same bone. Modeling of exact geometrical tibia including cortical and spongy bone using human bone CT scan images and mechanical validating of obtained model, is the aim of this study .The model produced by the current study supplies a tool for simulating mechanical test conditions on human tibia.

Numerical Investigation of Laser Surface Hardening of AISI 4340 Using 3D FEM Model for Thermal Analysis of Different Laser Scanning Patterns

Laser surface hardening is becoming one of the most successful heat treatment processes for improving wear and fatigue properties of steel parts. In this process, the heating system parameters and the material properties have important effects on the achieved hardened surface characteristics. The control of these variables using predictive modeling strategies leads to the desired surface properties without following the fastidious trial and error method. However, when the dimensions of the surface to be treated are larger than the cross section of the laser beam, various laser scanning patterns can be used. Due to their effects on the hardened surface properties, the attributes of the selected scanning patterns become significant variables in the process. This paper presents numerical and experimental investigations of four scanning patterns for laser surface hardening of AISI 4340 steel. The investigations are based on exhaustive modelling and simulation efforts carried out using a 3D finite element thermal analysis and structured experimental study according to Taguchi method. The temperature distribution and the hardness profile attributes are used to evaluate the effects of heating parameters and patterns design parameters on the hardened surface characteristics. This is very useful for integrating the scanning patterns’ features in an efficient predictive modeling approach. A structured experimental design combined to improved statistical analysis tools is used to assess the 3D model performance. The experiments are performed on a 3 kW Nd:Yag laser system. The modeling results exhibit a great agreement between the predicted and measured values for the hardened surface characteristics. The model evaluation reveals also its ability to provide not only accurate and robust predictions of the temperature distribution and the hardness profile as well an in-depth analysis of the effects of the process parameters.

3D finite element analysis of a two-surface wear model in fretting tests

This article aims at developing a computationally efficient framework to simulate the erosion of two contact surfaces in three-dimensional(3D),depending on the body resistance.The framework involves finite element(FE)resolution of a fretting problem,wear computation via a non-local criterion including a wear distribution parameter(WDP),as well as updating of the geometry and automatic remeshing.Its originality is based on the capability to capture the damage on each surface and obtain local and global results for a quantitative and qualitative analysis.Numerical simulations are carried out for two 3D contact specimens with different values of WDP.The results highlight the importance of correctly modelling wear:One-surface wear model is sufficient from a global point of view(wear volume),or whenever the wear resistance for a body is much higher than that of another one,whereas a 3D two-surface wear model is essential to capturing local effects(contact pressure,wear footprint,etc.)related to the difference in wear resistance of the bodies.

磁矢量势的全球电磁感应时间域三维有限元正演计算方法

全球电磁感应测深方法能获得地球深部电导率结构分布,目前被广泛应用于地球内部结构与热状态研究.地磁台站与地磁卫星观测的电磁感应数据为时间序列信号,在时间域分析全球电磁感应数据,特别是分析频谱极宽的磁暴脉冲响应,具有天然的优势.然而,当前的全球电磁感应数据解释技术一般在频率域进行,缺少时间域中的研究成果.为了弥补缺少时间域全球电磁感应数据解释方法的问题,本文开发了一种基于磁场矢量势的全球电磁感应时间域三维有限元并行正演求解方法,具备高精度快速计算源于地球外部时变电流源的地球感应电磁场时间序列的能力,特别适合于计算与分析频谱极宽的磁暴脉冲电磁感应时变响应.首先,建立基于磁场矢量势的全球电磁感应时间域微分控制方程,结合磁层外部电流源的物理属性建立边界条件和初始条件,从而构建出全球电磁感应时间域初始边界值问题.然后,利用四面体矢量有限元技术和无条件稳定的隐式后退欧拉公式,分别实现磁场矢量势的空间域和时间域离散,进而获得不同时刻的实系数大型有限元线性方程组,借助于高性能并行直接求解器,快速高精度地求解不同时刻的磁场矢量势与感应磁场.最后,利用理论模型验证本文算法的正确性.利用Dst磁暴环电流指数建立的时间域电流源与真实地球三维电性模型,研究"澳科一号"后续卫星200 km轨道对中国和澳大利亚下方地幔转换带高导体的探测能力,结果表明这些地幔转换带异常体在200 km卫星轨道高度能产生明显异常.综上所述,本文开发的时间域全球电磁感应方法不仅具备精确快速计算全球感应电磁场时间序列响应的能力,还能为反演与解释"澳科一号"等我国地磁卫星观测数据提供技术支持.

Finite element modelling and experimental investigation of the impact of filling different materials in copper tubes during 3D free bending process

3D free bending process,an advanced metal forming technology,has attracted much attention due to its unique geometrical flexibility and efficiency.Filling tubes with materials may effectively reduce the distortion in the cross-section area and restrain wrinkling and collapse of tube wall.In the present study,the impacts of filling different materials on the copper tubes during 3D free bending process were investigated.We have found that copper tubes filled with low melting point alloys could induce the most uniform stress distribution,which result in better formability and moderate thickness changing rates when compared to SS304 steel balls and PU rubbers.The lowest ellipticity reached to 1.467%.

Accurate 3D Reconstruction of Subject-Specific Knee Finite Element Model to Simulate the Articular Cartilage Defects

The biomechanical relationship between the articular cartilage defect and knee osteoarthritis (OA) has not been clearly defined. This study presents a 3D knee finite element model (FEM) to determine the effect of cartilage defects on the stress distribution around the defect rim. The complete knee FEM, which includes bones, articular cartilages, menisci and ligaments, is developed from computed tomography and magnetic resonance images. This FEM then is validated and used to simulate femoral cartilage defects. Based on the obtained results, it is confirmed that the 3D knee FEM is reconstructed with high-fidelity level and can faithfully predict the knee contact behavior. Cartilage defects drastically affect the stress distribution on articular cartilages. When the defect size was smaller than 1.00cm2, the stress elevation and redistribution were found undistinguishable. However, significant stress elevation and redistribution were detected due to the large defect sizes ( 1.00cm2). This alteration of stress distribution has important implications relating to the progression of cartilage defect to OA in the human knee joint.

Benchmarking of two three-dimensional numerical models in time/space domain to predict railway-induced ground vibrations

In the last 30 years,the scientific community has developed and proposed different models and numerical approaches for the study of vibrations induced by railway traffic.Most of them are formulated in the frequency/wave number domain and with a 2.5D approach.Three-dimensional numerical models formulated in the time/space domain are less frequently used,mainly due to their high computational cost.Notwithstanding,these models present very attractive characteristics,such as the possibility of considering nonlinear behaviors or the modelling of excess pore pressure and non-homogeneous and non-periodic geometries in the longitudinal direction of the track.In this study,two 3D numerical approaches formulated in the time/space domain are compared and experimentally validated.The first one consists of a finite element approach and the second one of a finite difference approach.The experimental validation in an actual case situated in Carregado(Portugal)shows an acceptable fitting between the numerical results and the actual measurements for both models.However,there are some differences among them.This study therefore includes some recommendations for their use in practical soil dynamics and geotechnical engineering.

ANN Based Predictive Modelling of Weld Shape and Dimensions in Laser Welding of Galvanized Steel in Butt Joint Configurations

The quality assessment and prediction becomes one of the most critical requirements for improving reliability, efficiency and safety of laser welding. Accurate and efficient model to perform non-destructive quality estimation is an essential part of this assessment. This paper presents a structured and comprehensive approach developed to design an effective artificial neural network based model for weld bead geometry prediction and control in laser welding of galvanized steel in butt joint configurations. The proposed approach examines laser welding parameters and conditions known to have an influence on geometric characteristics of the welds and builds a weld quality prediction model step by step. The modelling procedure begins by examining, through structured experimental investigations and exhaustive 3D modelling and simulation efforts, the direct and the interaction effects of laser welding parameters such as laser power, welding speed, fibre diameter and gap, on the weld bead geometry (i.e. depth of penetration and bead width). Using these results and various statistical tools, various neural network based prediction models are developed and evaluated. The results demonstrate that the proposed approach can effectively lead to a consistent model able to accurately and reliably provide an appropriate prediction of weld bead geometry under variable welding conditions.

A Three-Dimensional Numerical Model for Predicting the Weld Bead Geometry Characteristics in Laser Overlap Welding of Low Carbon Galvanized Steel

Laser welding (LW) becomes one of the most economical high quality joining processes. LW offers the advantage of very controlled heat input resulting in low distortion and the ability to weld heat sensitive components. To exploit efficiently the benefits presented by LW, it is necessary to develop an integrated approach to identify and control the welding process variables in order to produce the desired weld characteristics without being forced to use the traditional and fastidious trial and error procedures. The paper presents a study of weld bead geometry characteristics prediction for laser overlap welding of low carbon galvanized steel using 3D numerical modelling and experimental validation. The temperature dependent material properties, metallurgical transformations and enthalpy method constitute the foundation of the proposed modelling approach. An adaptive 3D heat source is adopted to simulate both keyhole and conduction mode of the LW process. The simulations are performed using 3D finite element model on commercial software. The model is used to estimate the weld bead geometry characteristics for various LW parameters, such as laser power, welding speed and laser beam diameter. The calibration and validation of the 3D numerical model are based on experimental data achieved using a 3 kW Nd:Yag laser system, a structured experimental design and confirmed statistical analysis tools. The results reveal that the modelling approach can provide not only a consistent and accurate prediction of the weld characteristics under variable welding parameters and conditions but also a comprehensive and quantitative analysis of process parameters effects on the weld quality. The results show great concordance between predicted and measured values for weld bead geometry characteristics, such as depth of penetration, bead width at the top surface and bead width at the interface between sheets, with an average accuracy greater than 95%.

Large-scale two-dimensional nonlinear FE analysis on PGA amplification effect with depth and focusing effect of Fuzhou Basin

Based on the explicit finite element(FE) method and platform of ABAQUS,considering both the inhomogeneity of soils and concave-convex fluctuation of topography,a large-scale refined two-dimensional(2D) FE nonlinear analytical model for Fuzhou Basin was established.The peak ground motion acceleration(PGA) and focusing effect with depth were analyzed.Meanwhile,the results by wave propagation of one-dimensional(1D) layered medium equivalent linearization method were added for contrast.The results show that:1) PGA at different depths are obviously amplified compared to the input ground motion,amplification effect of both funnel-shaped depression and upheaval areas(based on the shape of bedrock surface) present especially remarkable.The 2D results indicate that the PGA displays a non-monotonic decreasing with depth and a greater focusing effect of some particular layers,while the 1D results turn out that the PGA decreases with depth,except that PGA at few particular depth increases abruptly; 2) To the funnel-shaped depression areas,PGA amplification effect above 8 m depth shows relatively larger,to the upheaval areas,PGA amplification effect from 15 m to 25 m depth seems more significant.However,the regularities of the PGA amplification effect could hardly be found in the rest areas; 3) It appears a higher regression rate of PGA amplification coefficient with depth when under a smaller input motion; 4) The frequency spectral characteristic of input motion has noticeable effects on PGA amplification tendency.

Evolution of 3D tectonic stress field and fault movement in North China

Based on data of fault movement surveying, we simulate the evolution process of three dimensional stress field in North China by three dimensional finite element method. Evolutional patterns in one-year time scale from 1986 to 1997 have been illustrated and the evolution characteristics of stress field have been analyzed. In comparison with the seismic activity among that time interval in North China, we have primarily discussed the relationship between the evolution of stress field and seismic activity.

Nonlinear Switching Transient Field Simulation of Cable Joint without Residual Charge

The analysis of the impulse voltage on the internal electric field of the cable joint plays a key role in studying the breakdown of the joint. Based on the finite element method, a three-dimensional electromagnetic field simulation model of the cable joint is established in this paper. Simulation results show that the voltage at the head of the cable joint reaches about twice the impulse voltage. The increase of the conductivity of semi-conductive material also leads to the increase of electric field intensity. Then, several points and curves at different positions are selected for further analysis in this paper. Among them, the electric field distortion at the edge of the high voltage shield is the most serious and the electric field in the air gap is the least.

3-D Modelling of the Confederation Bridge Using Data of Full Scale Tests

Long-span bridges are special structures that require advanced analysis techniques to examine their performance. This paper presents a procedure developed to model the Confederation Bridge using 3-D beam elements. The model was validated using the data collected before the opening of the bridge to the public. The bridge was instrumented to conduct fullscale static and dynamic tests. The static tests were to measure the deflection of the bridge pier while the dynamic tests to measure the free vibrations of the pier due to a sudden release of the static load. Confederation Bridge is one of the longest reinforced concrete bridges in the world. It connects the province of Prince Edward Island and the province of New Brunswick in Canada. Due to its strategic location and vital role as a transportation link between these two provinces, it was designed using higher safety factors than those for typical highway bridges. After validating the present numerical model, a procedure was developed to evaluate the performance of similar bridges subjected to traffic and seismic loads. It is of interest to note that the foundation stiffness and the modulus of elasticity of the concrete have significant effects on the structural responses of the Confederation Bridge.

液压绞车结构设计及其有限元分析

采用三维设计软件对一款液压绞车进行了结构设计,介绍了其工作原理。通过对液压绞车的强度和刚性分析,得出其卷筒为关键结构件。采用ANSYS有限元软件对液压绞车中的卷筒进行了三维建模和应力、变形研究。通过有限元分析,说明了该液压绞车中卷筒的机械结构强度及刚度符合要求。

基于位移逆Krylov子空间的全波形航空瞬变电磁法三维数值模拟和响应特征

为了研究复杂地电模型的航空瞬变电磁法全波形响应特征,需要开发考虑发射波形的三维数值模拟算法。本研究基于非结构四面体网格和位移逆Krylov子空间(Shift-and-Invert Krylov,简称SAI Krylov)方法,采用基于电偶极子离散的场源处理方法模拟场源,在时间域进行计算实现了全波形航空瞬变电磁法矢量有限元三维数值模拟。使用均匀半空间模型在阶跃波、半正弦波、三角波和梯形波激发下的全波形解析解、VTEM实际激发波形的后推欧拉算法计算结果,检验了本研究开发的数值模拟算法的正确性。设计地表起伏异常体模型,计算和分析了航空瞬变电磁响应特征。开发的基于位移逆Krylov子空间的全波形航空瞬变电磁法三维数值模拟算法适合模拟复杂地电模型的响应,具有较高的计算精度。

Stochastic analysis of excavation-induced wall deflection and box culvert settlement considering spatial variability of soil stiffness

In this study, a three-dimensional (3D) finite element modelling (FEM) analysis is carried out to investigate the effects of soil spatial variability on the response of retaining walls and an adjacent box culvert due to a braced excavation. The spatial variability of soil stiffness is modelled using a variogram and calibrated by high-quality experimental data. Multiple random field samples (RFSs) of soil stiffness are generated using geostatistical analysis and mapped onto a finite element mesh for stochastic analysis of excavation-induced structural responses by Monte Carlo simulation. It is found that the spatial variability of soil stiffness can be described by an exponential variogram, and the associated vertical correlation length is varied from 1.3 m to 1.6 m. It also reveals that the spatial variability of soil stiffness has a significant effect on the variations of retaining wall deflections and box culvert settlements. The ignorance of spatial variability in 3D FEM can result in an underestimation of lateral wall deflections and culvert settlements. Thus, the stochastic structural responses obtained from the 3D analysis could serve as an effective aid for probabilistic design and analysis of excavations.